Thermal storage evaporator and system

ABSTRACT

A control module for a heating, ventilating, and air conditioning system includes a housing having an air flow conduit formed therein. An evaporator core is disposed in the air flow conduit, wherein at least a portion of the evaporator is configured to receive a first fluid from a first fluid source therein. An internal thermal energy exchanger is disposed in the air flow conduit downstream of at least a portion of the evaporator core and upstream of a blend door disposed in the air flow conduit. The internal thermal energy exchanger is configured to receive a second fluid from a second fluid source therein, wherein the first fluid is a refrigerant and the second fluid is at least one of a phase change material, a coolant, and a phase change material coolant.

FIELD OF THE INVENTION

The invention relates to a climate control system for a vehicle and moreparticularly to a heating, ventilating, and air conditioning system of avehicle having a thermal storage evaporator disposed therein.

BACKGROUND OF THE INVENTION

A vehicle typically includes a climate control system which maintains atemperature within a passenger compartment of the vehicle at acomfortable level by providing heating, cooling, and ventilation.Comfort is maintained in the passenger compartment by an integratedmechanism referred to in the art as a heating, ventilating and airconditioning (HVAC) system. The HVAC system conditions air flowingtherethrough and distributes the conditioned air throughout thepassenger compartment.

Typically, a compressor of a refrigeration system provides a flow of afluid having a desired temperature to an evaporator disposed in the HVACsystem to condition the air. The compressor is generally driven by afuel-powered engine of the vehicle. However, in recent years, vehicleshaving improved fuel economy over the fuel-powered engine and othervehicles are quickly becoming more popular as a cost of traditional fuelincreases. The improved fuel economy is due to known technologies suchas regenerative braking, electric motor assist, and engine-offoperation. Although the technologies improve fuel economy, accessoriespowered by the fuel-powered engine no longer operate when thefuel-powered engine is not in operation. One major accessory that doesnot operate is the compressor of the refrigeration system. Therefore,without the use of the compressor, the evaporator disposed in the HVACsystem does not condition the air flowing therethrough and thetemperature of the passenger compartment increases to a point above adesired temperature.

Accordingly, vehicle manufacturers have used a thermal energy exchangerdisposed in the HVAC system to condition the air flowing therethroughwhen the fuel-powered engine is not in operation. One such thermalenergy exchanger, also referred to as a cold accumulator, is describedin U.S. Pat. No. 6,854,513 entitled VEHICLE AIR CONDITIONING SYSTEM WITHCOLD ACCUMULATOR, hereby incorporated herein by reference in itsentirety. The cold accumulator includes a phase change material, alsoreferred to as a cold accumulating material, disposed therein. The coldaccumulating material absorbs heat from the air when the fuel-poweredengine is not in operation. The cold accumulating material is thenrecharged by the conditioned air flowing from the cooling heat exchangerwhen the fuel-powered engine is in operation.

In U.S. Pat. No. 6,691,527 entitled AIR-CONDITIONER FOR A MOTOR VEHICLE,hereby incorporated herein by reference in its entirety, a thermalenergy exchanger is disclosed having a phase change material disposedtherein. The phase change material of the thermal energy exchangerconditions a flow of air through the HVAC system when the fuel-poweredengine of the vehicle is not in operation. The phase change material ischarged by a flow of a fluid from the refrigeration system therethrough.

While the prior art HVAC systems perform adequately, it is desirable toproduce a thermal energy exchanger for an HVAC system having a coolantcirculating in at least a portion thereof, wherein an effectiveness andefficiency thereof are maximized.

SUMMARY OF THE INVENTION

In concordance and agreement with the present invention, a thermalenergy exchanger for an HVAC system having a coolant circulating in atleast a portion thereof, wherein an effectiveness and efficiency thereofare maximized, has surprisingly been discovered.

In one embodiment, a control module for a heating, ventilating, and airconditioning system, comprises: a housing having an air flow conduitformed therein; an evaporator core disposed in the air flow conduit, atleast a portion of the evaporator core configured to receive a firstfluid from a first fluid source therein; and an internal thermal energyexchanger disposed in the air flow conduit downstream of the at least aportion the evaporator core and upstream of a blend door disposed in theair flow conduit, the internal thermal energy exchanger configured toreceive a second fluid from a second fluid source therein, wherein thefirst fluid and the second fluid are different fluid types.

In another embodiment, a control module for a heating, ventilating, andair conditioning system, comprises: a housing having an air flow conduitformed therein; and an evaporator core having a plurality of layersdisposed in the air flow conduit, wherein at least one of the layers isconfigured to receive a first fluid from a first fluid source thereinand at least another one of the layers is configured to receive a secondfluid from a second fluid source therein, wherein the first fluid andthe second fluid are different fluid types.

In yet another embodiment, a control module for a heating, ventilating,and air conditioning system, comprises: a housing having an air flowconduit formed therein; an evaporator core disposed in the air flowconduit, the evaporator core configured to receive a first fluid from afirst fluid source therein; and an internal thermal energy exchangerdisposed in the air flow conduit downstream and spaced apart from theevaporator core and upstream of a blend door disposed in the air flowconduit, the internal thermal energy exchanger configured to receive asecond fluid from a second fluid source therein, wherein the first fluidis a refrigerant and the second fluid is a coolant.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, as well as other objects and advantages of the invention,will become readily apparent to those skilled in the art from readingthe following detailed description of various embodiments of theinvention when considered in the light of the accompanying drawings inwhich:

FIG. 1 is a schematic flow diagram of an HVAC system including afragmentary sectional view of an HVAC module having an evaporator coredisposed therein according to an embodiment of the invention and showingthe evaporator core in fluid communication with a first fluid source anda second fluid source, wherein the second fluid source is a fluidreservoir;

FIG. 2 is a schematic perspective view of the evaporator coreillustrated in FIG. 1 showing a portion of two layers of the evaporatorcore cutaway;

FIG. 3 is a schematic flow diagram of an HVAC system including afragmentary sectional view of an HVAC module having an evaporator coredisposed therein according to an embodiment of the invention and showingthe evaporator core in fluid communication with a first fluid source anda second fluid source, wherein the second fluid source is an externalthermal energy exchanger;

FIG. 4 is a schematic flow diagram of an HVAC system including afragmentary sectional view of an HVAC module having an evaporator coredisposed therein according to another embodiment of the invention andshowing a layer of the evaporator core spaced apart from adjacent layersthereof; and

FIG. 5 is a schematic flow diagram of an HVAC system including afragmentary sectional view of an HVAC module having an evaporator coreand an internal thermal energy exchanger disposed therein according toanother embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The following detailed description and appended drawings describe andillustrate various exemplary embodiments of the invention. Thedescription and drawings serve to enable one skilled in the art to makeand use the invention, and are not intended to limit the scope of theinvention in any manner.

FIG. 1 shows a heating, ventilating, and air conditioning (HVAC) system10 according to an embodiment of the invention. The HVAC system 10typically provides heating, ventilation, and air conditioning for apassenger compartment of a vehicle (not shown). The HVAC system 10includes a control module 12 to control at least a temperature of thepassenger compartment.

The module 12 illustrated includes a hollow main housing 14 with an airflow conduit 15 formed therein. The housing 14 includes an inlet section16, a mixing and conditioning section 18, and an outlet and distributionsection (not shown). In the embodiment shown, an air inlet 22 is formedin the inlet section 16. The air inlet 22 is in fluid communication witha supply of air (not shown). The supply of air can be provided fromoutside of the vehicle, recirculated from the passenger compartment ofthe vehicle, or a mixture of the two, for example. The inlet section 16is adapted to receive a blower wheel (not shown) therein to cause air toflow through the air inlet 22. A filter (not shown) can be providedupstream, in, or downstream of the inlet section 16 in respect of adirection of flow through the module 12 if desired.

The mixing and conditioning section 18 of the housing 14 is configuredto receive an evaporator core 24 and a heater core 28 therein. As shown,at least a portion of the mixing and conditioning section 18 is dividedinto a first passage 30 and a second passage 32. In particularembodiments, the evaporator core 24 is disposed upstream of aselectively positionable blend door 34 in respect of the direction offlow through the module 12 and the heater core 28 is disposed in thesecond passage 32 downstream of the blend door 34 in respect of thedirection of flow through the module 12. A filter (not shown) can alsobe provided upstream of the evaporator core 24 in respect of thedirection of flow through the module 12, if desired.

The evaporator core 24 of the present invention, shown in FIGS. 1-2, isa multi-layer louvered-fin thermal energy exchanger. In a non-limitingexample, the evaporator core 24 has a first layer 40, a second layer 42,and a third layer 44 arranged substantially perpendicular to thedirection of flow through the module 12. Additional or fewer layers thanshown can be employed as desired. The layers 40, 42, 44 are arranged sothe second layer 42 is disposed downstream of the first layer 40 andupstream of the third layer 44 in respect of the direction of flowthrough the module 12. It is understood, however, that the layers 40,42, 44 can be arranged as desired. The layers 40, 42, 44 can be bondedtogether by any suitable method as desired such as brazing and welding,for example.

Each of the layers 40, 42, 44 of the evaporator core 24 includes anupper first fluid manifold 46, 48, 50 and a lower second fluid manifold52, 54, 56, respectively. A plurality of first tubes 58 extends betweenthe fluid manifolds 46, 52 of the first layer 40. A plurality of secondtubes 60 extends between the fluid manifolds 48, 54 of the second layer42. A plurality of third tubes 62 extends between the fluid manifolds50, 56 of the third layer 44. In particular embodiments, each of thefirst upper fluid manifolds 46, 48, 50 is an inlet manifold whichdistributes the fluid into at least a portion of the respective tubes58, 60, 62 and each of the second lower fluid manifolds 52, 54, 56 is anoutlet manifold which collects the fluid from at least a portion of therespective tubes 58, 60, 62.

Each of the tubes 58, 60, 62 is provided with louvered fins 64 formedthereon. The fins 64 abut an outer surface of the tubes 58, 60, 62 forenhancing thermal energy transfer of the evaporate core 24. Each of thefins 64 defines an air space 68 extending between the tubes 58, 60, 62.The tubes 58, 60, 62 of the evaporator core 24 can further include aplurality of internal fins (not shown) formed on an inner surfacethereof. The internal fins further enhance the transfer of thermalenergy of the evaporator core 24. It is understood, however, that theevaporator core 24 can be constructed as a finless thermal energyexchanger if desired.

In a particular embodiment, the layers 40, 42 of the evaporator core 24,shown in FIG. 1, are in fluid communication with a first fluid source 70via a conduit 72. The first fluid source 70 includes a compressor 74 tocause a first fluid to circulate therein. Each of the layers 40, 42 isconfigured to receive a flow of the first fluid from the first fluidsource 70 therein. The first fluid absorbs thermal energy to conditionthe air flowing through the HVAC module 12 when a fuel-powered engine ofthe vehicle, and thereby the compressor 74, is in operation. As anon-limiting example, the first fluid source 70 is a refrigerationcircuit, and the first fluid is a refrigerant such as R134a, HFO-1234yf,AC-5, AC-6, and CO₂, for example. A valve 76 can be disposed in theconduit 72 to selectively militate against the flow of the first fluidtherethrough.

In certain embodiments, the HVAC system 10 includes an internal thermalenergy exchanger in fluid communication with a second fluid source 80via a conduit 82. The second fluid source 80 includes a pump 84 (e.g. anelectrical coolant pump) to cause a second fluid to circulate throughthe internal thermal energy exchanger. As illustrated, the internalthermal energy exchanger is the layer 44 of the evaporator core 24. Thelayer 44 is configured to receive a flow of the second fluid from thesecond fluid source 80 therein. The second fluid absorbs or releasesthermal energy to condition the air flowing through the HVAC module 12.A valve 86 can be disposed in the conduit 82 to selectively militateagainst the flow of the second fluid therethrough. As a non-limitingexample, the second fluid source 80 is a fluid reservoir containing aphase change material (PCM) therein. Those skilled in the art willappreciate that the phase change material can be any suitable materialthat melts and solidifies at predetermined temperatures and is capableof storing and releasing thermal energy such as organic, inorganic,eutectic and ionic liquids (e.g. a paraffin, a paraffin wax, an alcohol,water, a polygycol, a glycol), and the like, or any combination thereof,for example. The phase change material can also be impregnated with athermally conductive material such as graphite powder, for example, tofurther enhance the transfer of thermal energy. As another non-limitingexample, the second fluid source 80 is a fluid reservoir containing acoolant therein. As another non-limiting example, the second fluidsource 80 is a fluid reservoir containing a phase change materialcoolant such as CryoSolplus, for example, therein. As yet anothernon-limiting example shown in FIG. 3, the second fluid source 80 is anexternal thermal energy exchanger (e.g. a shell and tube heat exchanger,a chiller, etc.) in fluid communication with at least one other system90 of the vehicle via a conduit 92. It is understood that the externalthermal energy exchanger may include a phase change material disposedtherein if desired.

In another particular embodiment, the layers 40, 44 of the evaporatorcore 24 are in fluid communication with the first fluid source 70 viathe conduit 72 and configured to receive the flow of the first fluidtherein. On the other hand, the layer 42 of the evaporator core 24 is influid communication with the second fluid source 80 via the conduit 82and configured to receive the flow of the second fluid from the secondfluid source 80 therein.

In yet another particular embodiment, only the layer 40 of theevaporator core 24 is in fluid communication with the first fluid source70 via the conduit 72 and configured to receive the flow of the firstfluid therein. The layers 42, 44 of the evaporator core 24 are in fluidcommunication with the second fluid source 80 via the conduit 82 andconfigured to receive the flow of the second fluid from the second fluidsource 80 therein.

As shown, the heater core 28 is in fluid communication with a thirdfluid source 94 via a conduit 96. The heater core 28 is configured toreceive a flow of a third fluid from the third fluid source 94 therein.The third fluid source 94 can be any conventional source of heated fluidsuch as the fuel-powered engine or a battery system of the vehicle, forexample, and the third fluid can be any conventional fluid such as aphase change material, a coolant, or a phase change material coolant,for example. A valve 98 can be disposed in the conduit 96 to selectivelymilitate against the flow of the third fluid therethrough. The heatercore 28 is configured to facilitate a release of thermal energy from thethird fluid to heat the air flowing therethrough when the fuel-poweredengine of the vehicle is in operation.

FIG. 4 shows an alternative embodiment of the HVAC system 10 illustratedin FIGS. 1-3. Structure similar to that illustrated in FIGS. 1-3includes the same reference numeral and a prime (′) symbol for clarity.In FIG. 4, the HVAC system 10′ is substantially similar to the HVACsystem 10, except a layer 44′, which is the internal thermal energyexchanger in fluid communication with the second fluid source 80′, ofthe evaporator core 24′ is spaced apart from the layers 40′, 42′ of theevaporator core 24′.

It is understood that the operation of the HVAC system 10 including thethermal energy exchanger 26 is substantially similar to the operation ofthe HVAC system 10′. For simplicity, only the operation of the HVACsystem 10 including the thermal energy exchanger 26 is describedhereinafter.

In operation, the HVAC system 10 conditions air by heating or coolingthe air, and providing the conditioned air to the passenger compartmentof the vehicle. Air from the supply of air is received in the inletsection 16 of the housing 14 in the air inlet 22 and flows through thehousing 14 of the module 12.

In a cooling mode or an engine-off cooling mode of the HVAC system 10,the blend door 34 is positioned in one of a first position permittingair from the evaporator core 24 to only flow into the first passage 30,a second position permitting the air from the evaporator core 24 to onlyflow into the second passage 32, and an intermediate position permittingthe air from the evaporator core 24 to flow through both the firstpassage 30 and the second passage 32. In a heating mode or an engine-offheating mode of the HVAC system 10, the blend door 34 is positionedeither in the second position permitting the air from the evaporatorcore 24 to only flow into the second passage 32 and through the heatercore 28 or in the intermediate position permitting the air from theevaporator core 24 to flow through the first passage 30 and the secondpassage 32 and through the heater core 28. In an internal thermal energyexchanger charge mode or a re-circulation heating mode of the HVACsystem 10, the blend door 34 is positioned in one of the first positionpermitting the air from the evaporator core 24 to only flow into thefirst passage 30, the second position permitting the air from theevaporator core 24 to only flow into the second passage 32, and theintermediate position permitting the air from the evaporator core 24 toflow through both the first passage 30 and/or the second passage 32.

When the fuel-powered engine of the vehicle is in operation and the HVACsystem 10 is the cooling mode or the internal thermal energy exchangercharge mode, the first fluid from the first fluid source 70 circulatesthrough the conduit 72 to the layers 40, 42 as shown in FIG. 1, thelayers 40, 44, or only the layer 40 of the evaporator core 24.Additionally, the second fluid from the second fluid source 80circulates through the conduit 82 to the layer 44 as shown in FIG. 1,the layer 42, or both the layers 42, 44 of the evaporator core 24.Accordingly, the air from the inlet section 16 flows into the evaporatorcore 24 where the air is cooled to a desired temperature by a transferof thermal energy from the air to the first fluid from the first fluidsource 70. As the conditioned air flows through the evaporator core 24,the conditioned air absorbs thermal energy from the second fluid. Thetransfer of thermal energy from the second fluid to the conditioned aircools the second fluid, and thereby the phase change material, thecoolant, the phase change material coolant, or any combination thereofin the second fluid source 80. The conditioned air then exits theevaporator core 24 and is selectively permitted by the blend door 34 toflow through the first passage 30 and/or the second passage 32.

In other certain embodiments, when the fuel-powered engine of thevehicle is in operation and the HVAC system 10 is in the cooling mode,the first fluid from the first fluid source 70 circulates through theconduit 72 to the layers 40, 42 as shown in FIG. 1, the layers 40, 44,or only the layer 40 of the evaporator core 24. However, the pump 84 isnot in operation or the valve 86 is closed to militate against thecirculation of the second fluid from the second fluid source 80 throughthe conduit 82 to the layer 44 as shown in FIG. 1, the layer 42, or boththe layers 42, 44 of the evaporator core 24. Accordingly, the air fromthe inlet section 16 flows into the evaporator core 24 where the air iscooled to a desired temperature by a transfer of thermal energy from theair to the first fluid from the first fluid source 70. The conditionedair then exits the evaporator core 24 and is selectively permitted bythe blend door 34 to flow through the first passage 30 and/or the secondpassage 32.

When the fuel-powered engine of the vehicle is not in operation and theHVAC system 10 is in the engine-off cooling mode, the first fluid fromthe first fluid source 70 does not circulate through the conduit 72 tothe layers 40, 42 as shown in FIG. 1, the layers 40, 44, or only thelayer 40 of the evaporator core 24. However, the pump 84 causes thesecond fluid from the second fluid source 80 to circulate through theconduit 82 to the layer 44 as shown in FIG. 1, the layer 42, or both thelayers 42, 44 of the evaporator core 24. Accordingly, the air from theinlet section 16 flows into the evaporator core 24 where the air iscooled to a desired temperature by a transfer of thermal energy from theair to the second fluid from the second fluid source 80. The conditionedair then exits the evaporator core 24 and is selectively permitted bythe blend door 34 to flow through the first passage 30 and/or the secondpassage 32.

When the fuel-powered engine of the vehicle is in operation and the HVACsystem 10 is in the heating mode, the first fluid from the first fluidsource 70 does not circulate through the conduit 72 to the layers 40, 42as shown in FIG. 1, the layers 40, 44, or only the layer 40 of theevaporator core 24. Similarly, the pump 84 of the second fluid source 80is not in operation or the valve 86 is closed to militate against thecirculation of the second fluid from the second fluid source 80 throughthe conduit 82 to the layer 44 as shown in FIG. 1, the layer 42, or boththe layers 42, 44 of the evaporator core 24. Accordingly, the air fromthe inlet section 16 flows through the evaporator core 24 and theinternal thermal energy exchanger 144 where a temperature of the air isrelatively unaffected. The unconditioned air then exits the evaporatorcore 24 and is selectively permitted by the blend door 34 to flowthrough the first passage 30 and/or the second passage 32 through theheater core 28 to be heated to a desired temperature.

In other certain embodiments, when the fuel-powered engine of thevehicle is in operation and the HVAC system 10 is in the heating mode orthe fuel-powered engine of the vehicle is not in operation and the HVACsystem 10 is in the engine-off heating mode, the first fluid from thefirst fluid source 70 does not circulate through the conduit 72 to thelayers 40, 42 as shown in FIG. 1, the layers 40, 44, or only the layer40 of the evaporator core 24. However, the pump 84 causes the secondfluid from the second fluid source 80 to circulate through the conduit82 to the layer 44 as shown in FIG. 1, the layer 42, or both the layers42, 44 of the evaporator core 24. Accordingly, the air from the inletsection 16 flows into the evaporator core 24 where the air is heated toa desired temperature by a transfer of thermal energy from the secondfluid from the second fluid source 80 to the air flowing through theevaporator core 24. The conditioned air then exits the evaporator core24 and is selectively permitted by the blend door 34 to flow through thefirst passage 30 and/or the second passage 32 through the heater core 28to be further heated to a desired temperature.

When the fuel-powered engine of the vehicle is in operation and the HVACsystem 10 is in the recirculation heating mode or the internal thermalenergy exchanger charge mode, the first fluid from the first fluidsource 70 does not circulate through the conduit 72 to the layers 40, 42as shown in FIG. 1, the layers 40, 44, or only the layer 40 of theevaporator core 24. However, the pump 84 causes the second fluid fromthe second fluid source 80 to circulate through the conduit 82 to thelayer 44 as shown in FIG. 1, the layer 42, or both the layers 42, 44 ofthe evaporator core 24. Accordingly, a re-circulated air from apassenger compartment of the vehicle flow through the inlet section 16and into the evaporator core 24. As the re-circulated air flows throughthe evaporator core 24, the re-circulated air transfers thermal energyto the second fluid. The transfer of thermal energy from there-circulated air to the second fluid heats the second fluid, andthereby the phase change material, the coolant, the phase changematerial coolant, or any combination thereof in the second fluid source80. The re-circulated air then exits the evaporator core 24 and isselectively permitted by the blend door 34 to flow through the firstpassage 30 and/or the second passage 32.

FIG. 5 shows another an alternative embodiment of the HVAC system 10illustrated in FIGS. 1-4. Structure similar to that illustrated in FIGS.1-4 includes the same reference numeral and a double prime (″) symbolfor clarity. In FIG. 5, the HVAC system 10″ is substantially similar tothe HVAC system 10, except an internal thermal energy exchanger 144 isin fluid communication with the second fluid source 80″ instead of theevaporator core 24″.

The evaporator core 24″ of the present invention, shown in FIG. 5, is amulti-layer louvered-fin thermal energy exchanger. In a non-limitingexample, the evaporator core 24″ has a first layer 40″, a second layer42″, and a third layer 44″ arranged substantially perpendicular to thedirection of flow through a module 12″. Additional or fewer layers thanshown can be employed as desired. The layers 40″, 42″, 44″ are arrangedso the second layer 42″ is disposed downstream of the first layer 40″and upstream of the third layer 44″ in respect of the direction of flowthrough the module 12″. It is understood, however, that the layers 40″,42″, 44″ can be arranged as desired. The layers 40″, 42″, 44″ can bebonded together by any suitable method as desired such as brazing andwelding, for example.

The layers 40″, 42″, 44″ of the evaporator core 24″, shown in FIG. 5,are in fluid communication with a first fluid source 70″ via a conduit72″. The first fluid source 70″ includes a compressor 74″ to cause afirst fluid to circulate therein. Each of the layers 40″, 42″, 44″ isconfigured to receive a flow of the first fluid from the first fluidsource 70″ therein. The first fluid absorbs thermal energy to conditionthe air flowing through the HVAC module 12″ when a fuel-powered engineof the vehicle, and thereby the compressor 74″, is in operation. As anon-limiting example, the first fluid source 70″ is a refrigerationcircuit, and the first fluid is a refrigerant such as R134a, HFO-1234yf,AC-5, AC-6, and CO₂, for example. A valve 76″ can be disposed in theconduit 72″ to selectively militate against the flow of the first fluidtherethrough.

As shown, the internal thermal energy exchanger 144 of the HVAC system10″ is disposed downstream and spaced apart from the evaporator core 24″and upstream of a blend door 34″. The thermal energy exchanger 144 canbe any conventional thermal energy exchanger as desired such as amulti-layer louvered-fin thermal energy exchanger, for example. Thethermal energy exchanger is in fluid communication with a second fluidsource 80″ via a conduit 82″. The second fluid source 80″ includes apump 84″ (e.g. an electrical coolant pump) to cause a second fluid tocirculate through the internal thermal energy exchanger 144. Asillustrated, the internal thermal energy exchanger 144 is configured toreceive a flow of the second fluid from the second fluid source 80″therein. The second fluid absorbs or releases thermal energy tocondition the air flowing through the HVAC module 12″. A valve 86″ canbe disposed in the conduit 82″ to selectively militate against the flowof the second fluid therethrough. As a non-limiting example, the secondfluid source 80″ is a fluid reservoir containing a phase change material(PCM) therein. Those skilled in the art will appreciate that the phasechange material can be any suitable material that melts and solidifiesat predetermined temperatures and is capable of storing and releasingthermal energy such as organic, inorganic, eutectic and ionic liquids(e.g. a paraffin, a paraffin wax, an alcohol, water, a polygycol, aglycol), and the like, or any combination thereof, for example. Thephase change material can also be impregnated with a thermallyconductive material such as graphite powder, for example, to furtherenhance the transfer of thermal energy. As another non-limiting example,the second fluid source 80″ is a fluid reservoir containing a coolanttherein. As another non-limiting example, the second fluid source 80″ isa fluid reservoir containing a phase change material coolant such asCryoSolplus, for example, therein. As yet another non-limiting example,the second fluid source 80″ is an external thermal energy exchanger(e.g. a shell and tube heat exchanger, a chiller, etc.) in fluidcommunication with at least one other system 90″ of the vehicle via aconduit 92″. It is understood that the external thermal energy exchangermay include a phase change material disposed therein if desired.

As shown, the heater core 28″ is in fluid communication with a thirdfluid source 94″ via a conduit 96″. The heater core 28″ is configured toreceive a flow of a third fluid from the third fluid source 94″ therein.The third fluid source 94″ can be any conventional source of heatedfluid such as the fuel-powered engine or a battery system of thevehicle, for example, and the third fluid can be any conventional fluidsuch as a phase change material, a coolant, or a phase change materialcoolant, for example. A valve 98″ can be disposed in the conduit 96″ toselectively militate against the flow of the third fluid therethrough.The heater core 28″ is configured to facilitate a release of thermalenergy from the third fluid to heat the air flowing therethrough whenthe fuel-powered engine of the vehicle is in operation.

In operation, the HVAC system 10″ conditions air by heating or coolingthe air, and providing the conditioned air to the passenger compartmentof the vehicle. Air from the supply of air is received in housing 14″and flows through the module 12″.

In a cooling mode or an engine-off cooling mode of the HVAC system 10″,the blend door 34″ is positioned in one of a first position permittingair from the evaporator core 24″ and the thermal energy exchanger 144 toonly flow into the first passage 30″, a second position permitting theair from the evaporator core 24″ and the thermal energy exchanger 144 toonly flow into the second passage 32″, and an intermediate positionpermitting the air from the evaporator core 24″ and the thermal energyexchanger 144 to flow through both the first passage 30″ and the secondpassage 32″. In a heating mode or an engine-off heating mode of the HVACsystem 10″, the blend door 34″ is positioned either in the secondposition permitting the air from the evaporator core 24″ and the thermalenergy exchanger 144 to only flow into the second passage 32″ andthrough the heater core 28″ or in the intermediate position permittingthe air from the evaporator core 24″ and the thermal energy exchanger144 to flow through the first passage 30″ and the second passage 32″ andthrough the heater core 28″. In an internal thermal energy exchangercharge mode or a recirculation heating mode of the HVAC system 10″, theblend door 34″ is positioned in one of the first position permitting theair from the evaporator core 24″ and the thermal energy exchanger 144 toonly flow into the first passage 30″, the second position permitting theair from the evaporator core 24″ and the thermal energy exchanger 144 toonly flow into the second passage 32″, and the intermediate positionpermitting the air from the evaporator core 24″ and the thermal energyexchanger 144 to flow through both the first passage 30″ and/or thesecond passage 32″.

When the fuel-powered engine of the vehicle is in operation and the HVACsystem 10″ is in the cooling mode or the internal thermal energyexchanger charge mode, the first fluid from the first fluid source 70″circulates through the conduit 72″ to the layers 40″, 42″, 44″ of theevaporator core 24″. Additionally, the second fluid from the secondfluid source 80″ circulates through the conduit 82″ to the internalthermal energy exchanger 144. Accordingly, the air from the inletsection 16″ flows into the evaporator core 24″ where the air is cooledto a desired temperature by a transfer of thermal energy from the air tothe first fluid from the first fluid source 70″. The conditioned airthen flows from the evaporator core 24″ to the internal thermal energyexchanger 144. As the conditioned air flows through the internal thermalenergy exchanger 144, the conditioned air absorbs thermal energy fromthe second fluid. The transfer of thermal energy from the second fluidto the conditioned air cools the second fluid, and thereby the phasechange material, the coolant, the phase change material coolant, or anycombination thereof in the second fluid source 80″. The conditioned airthen exits the internal thermal energy exchanger 144 and is selectivelypermitted by the blend door 34″ to flow through the first passage 30″and/or the second passage 32″.

In other certain embodiments, when the fuel-powered engine of thevehicle is in operation and the HVAC system 10″ is operating in thecooling mode, the first fluid from the first fluid source 70″ circulatesthrough the conduit 72″ to the layers 40″, 42″, 44″ of the evaporatorcore 24″. However, the pump 84″ of the second fluid source 80″ is not inoperation or the valve 86″ is closed to militate against the circulationof the second fluid from the second fluid source 80″ through the conduit82″ to the internal thermal energy exchanger 144. Accordingly, the airfrom the inlet section 16″ flows into the evaporator core 24″ where theair is cooled to a desired temperature by a transfer of thermal energyfrom the air to the first fluid from the first fluid source 70″. Theconditioned air then flows from the evaporator core 24″ to the internalthermal energy exchanger 144. As the conditioned air flows through theinternal thermal energy exchanger 144, the temperature of theconditioned air is relatively unaffected. The conditioned air then exitsthe internal thermal energy exchanger 144 and is selectively permittedby the blend door 34″ to flow through the first passage 30″ and/or thesecond passage 32″.

When the fuel-powered engine of the vehicle is not in operation and theHVAC system 10″ is in the engine-off cooling mode, the first fluid fromthe first fluid source 70″ does not circulate through the conduit 72″ tothe layers 40″, 42″, 44″ of the evaporator core 24″. However, the pump84″ causes the second fluid from the second fluid source 80″ tocirculate through the conduit 82″ to the internal thermal energyexchanger 144. Accordingly, the air from the inlet section 16″ flowsthrough the evaporator core 24″ where a temperature of the air isrelatively unaffected. The air then flows from the evaporator core 24″to the internal thermal energy exchanger 144. As the air flows throughthe internal thermal energy exchanger 144, the air is cooled to adesired temperature by a transfer of thermal energy from the air to thesecond fluid from the second fluid source 80″. The conditioned air thenexits the thermal energy exchanger 144 and is selectively permitted bythe blend door 34″ to flow through the first passage 30″ and/or thesecond passage 32″.

When the fuel-powered engine of the vehicle is in operation and the HVACsystem 10″ is in the heating mode, the first fluid from the first fluidsource 70″ does not circulate through the conduit 72″ to the layers 40″,42″, 44″ of the evaporator core 24″. Similarly, the pump 84″ of thesecond fluid source 80″ is not in operation or the valve 86″ is closedto militate against the circulation of the second fluid from the secondfluid source 80″ through the conduit 82″ to the internal thermal energyexchanger 144. Accordingly, the air from the inlet section 16″ flowsthrough the evaporator core 24″ and the internal thermal energyexchanger 144 where a temperature of the air is relatively unaffected.The unconditioned air then exits the evaporator 24″ and the internalthermal energy exchanger 144 and is selectively permitted by the blenddoor 34″ to flow through the first passage 30″ and/or the second passage32″ through the heater core 28″ to be heated to a desired temperature.

In other certain embodiments, when the fuel-powered engine of thevehicle is in operation and the HVAC system 10″ is in the heating modeor the fuel-powered engine of the vehicle is not in operation and theHVAC system 10″ is in the engine-off heating mode, the first fluid fromthe first fluid source 70″ does not circulate through the conduit 72″ tothe layers 40″, 42″, 44″ of the evaporator core 24″. However, the pump84″ causes the second fluid from the second fluid source 80″ tocirculate through the conduit 82″ to the internal thermal energyexchanger 144. Accordingly, the air from the inlet section 16″ flowsthrough the evaporator core 24″ where a temperature of the air isrelatively unaffected. The air then flows from the evaporator core 24″to the internal thermal energy exchanger 144. As the air flows throughthe internal thermal energy exchanger 144, the air is heated to adesired temperature by a transfer of thermal energy from the secondfluid from the second fluid source 80″ to the air flowing through theinternal thermal energy exchanger 144. The conditioned air then exitsthe internal thermal energy exchanger 144 and is selectively permittedby the blend door 34″ to flow through the first passage 30″ and/or thesecond passage 32″ through the heater core 28″ to be further heated to adesired temperature.

When the fuel-powered engine of the vehicle is in operation and the HVACsystem 10″ is in the recirculation heating mode or the internal thermalenergy exchanger charge mode, the first fluid from the first fluidsource 70″ does not circulate through the conduit 72″ to the layers 40″,42″, 44″ of the evaporator core 24″. However, the pump 84″ causes thesecond fluid from the second fluid source 80″ to circulate through theconduit 82″ to the internal thermal energy exchanger 144. Accordingly, are-circulated air from a passenger compartment of the vehicle flowthrough the inlet section 16″ and into the evaporator core 24″ where atemperature of the air is relatively unaffected. The re-circulated airthen flows from the evaporator core 24″ to the internal thermal energyexchanger 144. As the air flows through the internal thermal energyexchanger 144, the re-circulated air transfers thermal energy to thesecond fluid. The transfer of thermal energy from the re-circulated airto the second fluid heats the second fluid, and thereby the phase changematerial, the coolant, the phase change material coolant, or anycombination thereof in the second fluid source 80″. The re-circulatedair then exits the internal thermal energy exchanger 144 and isselectively permitted by the blend door 34″ to flow through the firstpassage 30″ and/or the second passage 32″.

From the foregoing description, one ordinarily skilled in the art caneasily ascertain the essential characteristics of this invention and,without departing from the spirit and scope thereof, can make variouschanges and modifications to the invention to adapt it to various usagesand conditions.

What is claimed is:
 1. A control module for a heating, ventilating, andair conditioning system, comprising; a housing having an air flowconduit formed therein; an evaporator core disposed in the air flowconduit, at least a portion of the evaporator core configured to receivea first fluid from a first fluid source therein; and an internal thermalenergy exchanger disposed in the air flow conduit downstream of the atleast a portion the evaporator core and upstream of a blend doordisposed in the air flow conduit, the internal thermal energy exchangerconfigured to receive a second fluid from a second fluid source therein,wherein the first fluid and the second fluid are different fluid types.2. The control module of claim 1, wherein the internal thermal energyexchanger is another portion of the evaporator core.
 3. The controlmodule of claim 1, wherein the internal thermal energy exchanger is athermal energy exchanger separate from the evaporator core.
 4. Thecontrol module of claim 1, wherein the first fluid source is arefrigeration circuit.
 5. The control module of claim 1, wherein thesecond fluid source is a fluid reservoir containing at least one of aphase change material, a coolant, and a phase change material coolant.6. The control module of claim 1, wherein the second fluid source is anexternal thermal energy exchanger.
 7. The control module of claim 6,wherein the external thermal energy exchanger includes a phase changematerial disposed therein.
 8. A control module for a heating,ventilating, and air conditioning system, comprising: a housing havingan air flow conduit formed therein; and an evaporator core having aplurality of layers disposed in the air flow conduit, wherein at leastone of the layers is configured to receive a first fluid from a firstfluid source therein and at least another one of the layers isconfigured to receive a second fluid from a second fluid source therein,wherein the first fluid and the second fluid are different fluid types.9. The control module of claim 8, wherein the first fluid is arefrigerant and the second fluid is at least one of a phase changematerial, a coolant, and a phase change material coolant.
 10. Thecontrol module of claim 8, wherein the first fluid source is arefrigeration circuit.
 11. The control module of claim 8, wherein thesecond fluid source is a fluid reservoir containing at least one of aphase change material, a coolant, and a phase change material coolant.12. The control module of claim 8, wherein the at least another one ofthe layers of the evaporator core configured to receive the second fluidtherein is disposed downstream from the at least one layer of theevaporator core configured to receive the first fluid therein.
 13. Thecontrol module of claim 8, wherein the at least another one of thelayers of the evaporator core configured to receive the second fluidtherein is disposed between a plurality of the layers of the evaporatorcore configured to receive the first fluid therein.
 14. The controlmodule of claim 8, wherein the least another one of the layers of theevaporator core configured to receive the second fluid therein isdisposed downstream and spaced apart from the at least one layer of theevaporator core configured to receive the first fluid therein.
 15. Thecontrol module of claim 8, wherein the second fluid source is anexternal thermal energy exchanger.
 16. The control module of claim 15,wherein the external thermal energy exchanger includes a phase changematerial disposed therein.
 17. A control module for a heating,ventilating, and air conditioning system, comprising: a housing havingan air flow conduit formed therein; an evaporator core disposed in theair flow conduit, the evaporator core configured to receive a firstfluid from a first fluid source therein; and an internal thermal energyexchanger disposed in the air flow conduit downstream and spaced apartfrom the evaporator core and upstream of a blend door disposed in theair flow conduit, the internal thermal energy exchanger configured toreceive a second fluid from a second fluid source therein, wherein thefirst fluid is a refrigerant and the second fluid is at least one of aphase change material, a coolant, and a phase change material coolant.18. The control module of claim 17, wherein the first fluid source is arefrigeration circuit.
 19. The control module of claim 17, wherein thesecond fluid source is a fluid reservoir containing at least one of thephase change material, the coolant, and the phase change materialcoolant.
 20. The control module of claim 17, wherein the second fluidsource is an external thermal energy exchanger.